Actyx for Glass Manufacturing

Whether you manufacture glass for pharma, consumer goods or drinkware, Actyx can help.

CHALLENGE

Reliably producing high quality glass products comes with complex production processes. Hundreds of parameters such as batch composition, furnace temperature, plunger, scissor or gob ring wearing or outside temperature influence the production process outcome. Changeovers often lack clear SOPs and rely on operator skill-level and experience. Adding to this complexity come ever increasing quality standards, more complex products and smaller lot-sizes.

SOLUTION

Capture and centralize data end-to-end from your batch house, furnace control system, IS-machine, QA-machines and line counters to visualize the data in real-time in the Factory Supervision Dashboard. See the status of your IS-machines and the production line to identify problems and delays. Stay on top of your daily processes with the Daily Status Report that accurately summarizes the daily production output and job changes. Use the Process Data Visualization application to deep dive into your data for comparing parameters such as feeder temperature or machine cut speed with output to identify best-in-class settings. Improve flexibility and react quickly to problems through automatic SMS/Email notifications in case of machine interruptions or process anomalies using the Automatic Notification Service.

Capture and centralize data end-to-end from your batch house, furnace control system, IS-machine, QA-machines and line counters. The Factory Supervision Dashboard visualizes real-time order progress and status of IS-machine sections or QA-machines along the entire value stream. Stay on top of your daily processes with the Daily Status Report that accurately summarizes on daily production output and job changes. Use Process Data Visualization to deep dive into your data for comparing parameters such as feeder temperature or machine cut speed with output and pack to identify best-in-class settings. Set up triggers to notify your personnel in the hot end in case of deviations or interruptions with Automatic Notification Services.
Data solution for digital glass production

BENEFITS

For the worker

Work efficiently supported through quick access to most relevant information such as setup parameters.

For the manager

Reduce downtime and improve quality through implementation of data-driven improvement measures.

For the CEO/CFO

Drive down cost through higher efficiency. Increase sales through higher productivity and flexibility.

Want to learn how to translate data to business value?

GLASS APPS FOR REAL-TIME DATA

Configured based upon the Actyx Visual Management Dashboard and Mobile Team Collaboration application.

Real time line dashboard
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Hot-End Line Dashboard

Visualize your most important line data on IS-machine section status & downtimes, current order progress, feeder temperature or pack over time. Help your operators keep track of relevant data right on the shop-floor.

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Cold-End Line Dashboard

Visualize your cold-end line data including status of quality assurance machines, throughput per QA-machine as well as scrap per section. Help your supervisors to identify bottlenecks quickly and mitigate them swiftly.

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Factory Supervision Dashboard

Get 360º transparency on all production lines in real-time. Relevant information per line such as current order, target yield, IS-machine status, pack or OEE are displayed helping you to stay on top of your factory processes.

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Automatic Notification Service

Real-time SMS/Email notifications triggered by events or incidents such as exceeded thresholds on a set of parameters. Triggers and notifications are configured on production line, article, responsible stakeholders and more.

Factory Supervision Board

Success Story

Watch the video to learn how the Stölzle Glass Group leverages Actyx Glass Apps to improve their setup processes.

GLASS APPS FOR HISTORIC DATA

Configured based upon the Actyx Reporting & Analytics application.

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Daily Status Report

Summarize on a daily basis important information on line output such as output per line with comparison against production target, pack, number of job changes and information on OEE per line.

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OEE Report

Compare performance across production line through transparency on OEE per line over time. Display information on uptime, production speed and quality benchmarked with average and best day performance data.

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Process Data Visualization

Visualize process parameters such as temperature, pack or plunger heights over time. Compare these with output and quality data to identify ideal process parameters and to set anomaly thresholds.

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Job Change Report

Benchmark performance across your daily job-changes against best/average setups. Compare pack (12 hours), time for mechanical setup, cold/hot run and more for job-changes to continuously improve your setup processes.

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Weekly Output Report

Summarize on a weekly/monthly basis line output, including information on output per line with comparison against production target, pack, number of job changes and information on OEE per line.

GLASS APPS FOR MACHINE DATA

Configured based upon the Actyx Machine Data Collection application.

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Batch House Data Collection

Collect and aggregate data from batch house control systems or directly from PLCs to enable real-time as well as historic use. Track when which recipe has been set and what target/actual composition of components was.

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Furnace Data Collection

Enable real-time as well as historic access to furnace control systems data such as temperature per melting tank zone, feeder temperatures per zone and line, gas supply, power supply or air supply.

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Counter Data Aggregation

Collect and aggregate specific data from line counters to enable real-time as well as historic access. Track counter data per line section over time and correlate counter data with active production orders.

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QA-Machine Data Collection

Collect and aggregate specific data from QA-machines to enable real-time as well as historic access. Track throughput, scrap rate and scrap reason per QA-machine.

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IS-Machine Data Collection

Collect and aggregate specific data from IS-machines to enable real-time as well as historic access. Track machine counters per section, machine program, mechanism timing and other settings. Compute the status of each section from counter data.

Struggling which apps to choose? We’re here to help!

GLASS INTEGRATIONS

Integrations for glass manufacturing equipment and software.

Integration Flex-IS

Integrate to Emhart IS-machines to extract machine specific data such as machine section counters and machine settings.

Integration ODBC

Integration to your SQL database using Open Database Connectivity (ODBC) to extract data such as counter or quality data.

Integration Bottero IS

Integrate to Bottero IS-machines to extract machine specific data such as machine section counters and machine settings.

Integration Sklostroj-IS

Integrate to Sklostroj IS-machines to extract machine specific data such as machine section counters and machine settings.

Integration MS Azure SQL

Integrate to MS Azure SQL to export process data. Export to MS Power BI for specific reports, dashboards and further analysis.

Integration OPC UA/OPC DA

Integration with data sources such as furnace control systems using OPC UA/OPC DA to extract relevant data.

GUIDE: DATA IN GLASS MANUFACTURING

Guide - how to leverage data in glass manufacturing

How to leverage data to improve efficiency, today

A glass production is a complex system of workers, machines and material, orchestrated to generate high-quality products with the least amount of cost possible. From the batch house to the furnace, IS-machines or quality assurance systems, data is generated across the entire value stream.

Learn how you can ensure that data enables value from collecting and centralizing data across the entire value stream, generating insights through specific data reports and implementing improvement measures.

No IT project, no risk.

Step into the digital era. Headache-free. With the Actyx All-Inclusive Package.

Open questions?
Let us tackle them together: contact us
or call +49 (0)89 9439 7400